Reusable Non-Stick Epoxy Applicator with Flexible Lubricated Tip
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Solution Overview
Problem
Existing epoxy applicators are not reusable and lack flexibility, making it difficult to create a smooth epoxy surface on various surfaces.
Innovation Solution
A polymer extruded reusable non-stick epoxy applicator with a rigid handle and a flexible portion embedded with a permanently lubricating film, allowing for flexion and reducing friction, is developed. The applicator combines thermoplastic polyolefin and thermoplastic vulcanizate elastomer materials with a low coefficient of friction film, enabling smooth application of epoxy and other materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a reusable epoxy applicator is used, then cost-effectiveness and sustainability improve, but manufacturing complexity increases
Solution Approach 1:
The applicator combines thermoplastic polyolefin (rigid portion) and thermoplastic vulcanizate elastomer (flexible portion) with a permanently lubricating film in a single extrusion process. This composite material approach creates a multi-functional reusable applicator that integrates structural rigidity, flexibility, and non-stick properties, resolving the contradiction between reusability and manufacturing complexity.
2Ease of operation
If a flexible portion is added to the applicator, then ease of operation and surface smoothness improve, but structural complexity increases
Solution Approach 1:
The applicator is divided into two distinct segments: a rigid portion (durometer 50-80 Shore D) for structural support and handle attachment, and a flexible portion (durometer 40-60 Shore A) for surface conforming and smooth application. This segmentation allows each part to perform its specific function optimally while maintaining overall simplicity through single-process manufacturing.
Solution Approach 2:
Different portions of the applicator have different material properties tailored to their specific functions: the rigid portion provides structural integrity, while the flexible portion provides conformability and smooth surface application. The permanently lubricating film is applied locally to the interaction surfaces where epoxy contact occurs, enhancing non-stick properties where needed.
3Ease of operation
If a permanently lubricating film is applied to reduce friction, then epoxy application smoothness improves, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process merges multiple functions into a single extrusion operation: the rigid thermoplastic polyolefin, flexible thermoplastic vulcanizate elastomer, and permanently lubricating film are extruded simultaneously in one continuous process. This integration eliminates separate manufacturing steps for applying the lubricating film, resolving the contradiction between achieving smooth epoxy application and maintaining manufacturing simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a reusable applicator that effectively applies epoxy and other materials with reduced friction, ensuring a smooth surface and improved usability by allowing for flexion during application.
Implementation Method 1
a permanently lubricating film extending along said interaction surface and said opposite surface, the permanently lubricating film providing the interaction and opposite surfaces with a lower coefficient of friction than the rigid surface
Implementation Method 2
heating said first, second, and third materials within a heating section of the respective extruders
Implementation Method 3
heating said first, second, and third materials within a heating section of the respective extruders, feeding said first, second, and third materials from said heating sections into a die head, and forming a single extrusion
Data Source
AI summary
A reusable applicator for epoxy application and a method of manufacture are disclosed herein. The reusable applicator having a rigid portion configured to support a handle attached thereto, the rigid portion having a first durometer. The reusable applicator having a flexible portion extending from said rigid portion, the flexible portion having a second durometer, said first durometer being greater than said second durometer. The flexible portion further includes an interaction surface located on a first side of the flexible portion, an opposite surface located opposite the interaction surface of the flexible portion, and a permanently lubricating film extending along said interaction surface and said opposite surface, the interaction surface spaced from the opposite surface by the flexible portion, the permanently lubricating film providing the interaction and opposite surfaces with a lower coefficient of friction than the rigid surface. The reusable applicator manufactured using a single extrusion head.